Sealant System and Methods of Use and Manufacture

ABSTRACT

A roof sealing system method of manufacture and method of application comprising three parts: a caulk gap filler, a mastic, and a top coating. All three components combine to create a singular sealed membrane when applied to a roof surface. The roof sealing system utilizes inert polyethylene fibers in a liquid silicone polymer.

BACKGROUND OF THE INVENTION

This invention generally pertains to the field of sealants, and moreparticularly roofing sealants and waterproofing. More specifically, thisinvention relates to a fiber-infused caulk, mastic, and coating, as wellas a system and method for manufacture and application. While the caulklayer, mastic layer, and coating layer work as a system in thisembodiment, one of ordinary skill in the art would understand they canbe used individually as well.

Membrane roofing systems typically involve applying large pieces of asynthetic rubber, thermoplastic or modified bitumen material onto anunderlying roofing structure, such as plywood, and bonding or heatsealing seams together to form a continuous and coherent membranestructure that prevents water from penetrating the membrane andunderlying structures. Membrane roofing differs from asphalt and gravelroofing or shingle roofing in that it creates a single bonded membranestructure.

Synthetic rubber roofing uses sheets of rubber which are bonded togetheralong the edges to create a solid sealed layer. This results in seamswhere the rubber sheeting is bonded together, creating weak points wherewater leakage can occur. The most commonly used synthetic rubber isethylene propylene diene monomer (EPDM). EPDM and other synthetic rubberroofing materials can withstand ultraviolet radiation, are waterproof,puncture resistant and are chemically resistant.

Thermoplastics use lap joints to create a sealed surface. Sheets ofthermoplastic material are overlapped at the edges, and bonded togetherusing heat or solvents. Similar to synthetic rubber, this processcreates seams which are prone to water leakage. Thermoplastic roofingalso requires a fabric-based reinforcement layer under the thermoplasticsheeting. The most common form of thermoplastic roofing is polyvinylchloride (PVC).

Bitumen roofing is a layer of asphalt-based sheeting. Sheets of theasphalt material are sealed together by heating the asphalt. Thiscreates seams which are prone to leakage, and heating the asphaltreleases chemicals. The downside of the existing membrane options isthat they must have holes cut in them for vents and pipes, which mustthen be sealed with mastic, fabric, or asphalt to prevent waterinfiltration.

Conventional membrane roofing relies on the seals between individualsections of the roofing material being watertight. Likewise, the sealscreated around pipes and vents must be watertight. The three membraneroofing material types do not create an effective seamless barrier, asthe seams can be weaker than the material itself. Installation ofconventional membrane roofing can require equipment to heat and seal thejoints. It can also require significant experience to fit patches aroundpiping and vents in the roof. Additionally, current membrane roofingoptions also use and emit volatile organic compounds (VOC) duringinstallation and use because of VOC solvents used during production.There is, therefore, a present need for improvement and a moreuser-friendly option for roofing.

SUMMARY OF THE INVENTION

Described herein are various embodiments of systems, methods andcomponents for roofing material sealing and waterproofing.

In accordance with one embodiment, the system comprises a systemincluding a roof caulk, a roof mastic and a roof coating. In thisembodiment, the roof caulk fills seams, joints, cracks, and existingpenetrations such as pipes, vents, and edges. Roof caulk is the firstapplied layer of the roofing system. In this embodiment, the roof caulkmay be comprised of a fiber-infused silicone polymer resin, which mayoptional further include pigments, strengthening fillers and/or mineralfillers.

Additionally, the system comprises a roof mastic configured to coat thecaulk-filled seams, joints, cracks, or penetrations. Roof mastic is thesecond applied layer of the roofing system. In this embodiment, themastic creates a smooth surface for the coating to adhere to by sealingthe caulk into the gaps, crevices, and openings around vents and pipes.In this embodiment, the roof mastic may be comprised of fiber-infusedsilicone polymer resin with strengthening and mineral fillers. In someembodiments, cyclic siloxane is added to control viscosity.

Additionally, in this embodiment, the system comprises a roof coatingdesigned to coat the entire surface of the roof. Roof coating is thethird applied layer of the roofing system. The coating may be applied tothe entirety of the roof surface in two or more coats to ensure aseamless membrane is achieved. In this embodiment, the roof coating maybe comprised of a fiber-infused silicone polymer resin withstrengthening and mineral fillers. The fiber used in the siliconepolymer resin may be polymer, natural fibers such as cotton, flax, jute,hemp or sisal, cellulose, ceramic, glass or the like. In accordance withone embodiment, the fiber may be a plant fiber, mineral fiber, syntheticfiber, regenerated fiber, or semi-synthetic fiber. Synthetic fibers maybe selected from the group consisting of polyethylene, polyethyleneterephthalate, polyurethane, polypropylene, polyester, polyamide, nylon,polyacrylonitrile, poly-paraphenyulene terepthalamide, and aramids. Insome embodiments, cyclic siloxane may be added as a solvent to controlviscosity of the resin.

In operation of the system, the three components may be applied inseries to a roof to create a seamless, watertight membrane on the roofsurface. The roof sealing system may be applied on an existing membraneroof or directly on to the roof decking. The method of applying thesystem may comprise the steps of applying the roof caulk to fill largergaps in the roof substrate and sealing any penetrations around pipes,vents, edges, joints, seams, and cracks, then applying the mastic overthe caulk to create a sealed barrier wherein the mastic smooths thesurface in preparation for application of the coating, applying the roofcoating to the entirety of the roof, in two or more applications with aroller, brush, or spray, to completely seal the surface of the roof. Inthis embodiment, watertight barrier, which is cured by ambient moisture,is formed and requires no maintenance after initial installation. Byemploying fibers in the resin no fabric reinforcing layer is needed. Thelower viscosity of the roof sealing system allows for complete adherenceto the roof surface without the need for additional adhesives.

In one embodiment, the three components may be manufactured in a similarmethod with some variations in viscosity due to different length fibersor the addition of the cyclic siloxane solvent in the mastic and thecoating. First, silicone polymers are added to a mixing vessel andcombined with mineral fillers and strengthening fillers. In someembodiments, cyclic siloxane may be added as a solvent to reduceviscosity, and pigment may be added to the mixing vessel. A nitrogenpurge may be used to expel any excess air and moisture. In someembodiments, crosslinking agents may be added to obtain a desiredcrosslink density in the cured product, a adhesion promoter may be addedto ensure complete adherence to roofing substrates, and a catalyst maybe added to adjust the cure characteristics. In this embodiment, allingredients are mixed until they are homogenized completely. Finally, insome embodiments, the fibers may be added to the mixture to increasetenacity and scratch resistance.

The methods, systems, and apparatuses are set forth in part in thedescription which follows, and in part will be obvious from thedescription, or can be learned by practice of the methods, apparatuses,and systems. The advantages of the methods, apparatuses, and systemswill be realized and attained by means of the elements and combinationsparticularly pointed out in the appended claims. It is to be understoodthat both the foregoing general description and the following detaileddescription are exemplary and explanatory only and are not intended tobe restrictive of the methods, apparatuses, and systems, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying figures, like elements are identified by likereference numerals among the several preferred embodiments of thepresent invention.

FIG. 1A is a diagram illustrating the method of application of the roofsealing system to a roof surface.

FIG. 2A is a diagram illustrating the method of manufacture of thecaulk, mastic, and coating components of the roof sealing system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The foregoing and other features and advantages of the invention areapparent from the following detailed description of exemplaryembodiments, read in conjunction with the accompanying drawings. Thedetailed description and drawings are merely illustrative of theinvention rather than limiting, the scope of the invention being definedby the appended claims and equivalents thereof.

For purposes of clarity, the following terms used in this patentapplication will have the following meanings:

“Substantially” is intended to mean a quantity, property, or value thatis present to a great or significant extent and less than totally.

“About” is intended to mean a quantity, property, or value that ispresent at ±10%.

“Solvent” as used here is intended to mean any substance used to modifyviscosity.

In accordance with the present invention there is provided a roofsealing system (FIG. 1A). The system comprises generally a caulk layer,a mastic layer, and a coating layer. Each of the caulk layer, masticlayer, and coating layer comprise a fiber-infused silicone material. Asshown in FIG. 1A, the caulk layer is applied first to cracks, openings,joints, seams, vents, pipes, and crevices in the roofing substrate 510.The mastic layer is then overlaid 520 on the caulk layer and used tobuild up low areas to create a smooth surface to which the coating layermay adhere. The coating layer is then applied to the entirety of theroof surface in two or more coats to create a single, seamless, roofmembrane 530. The three components utilize a similar method ofmanufacture varying the process steps and process parameters.

Caulk

In one embodiment, the roof caulk is the first applied layer of theroofing system 510. The caulk creates a base layer for the masticoverlay and ensures small pockets of water will not occur on the roofsurface. The caulk is delivered by dispersing a bead into cracks, gaps,edges, and joints 510 from a standard caulk dispenser.

In this embodiment, the roof caulk may comprise a silicone polymerresin, strengthening fillers, mineral fillers, pigment, crosslinkingagents, adhesion promoters, a catalyst, and inert fiber combined underhigh shear mixing and blanketed by nitrogen.

In one aspect of the roof caulk, the silicone polymer resin comprises ahydroxyl-endcapped polydimethylsiloxane silanol fluid having a viscosityof 2,000 centipoise, specific gravity of 0.980, and refractive index of1.4058, at 25 degrees Celsius. Condensation curing is the mechanismemployed to cure the system, and achieved using a crosslinking agent andcatalyst, as discussed below.

In another aspect of the roof caulk, the strengthening filler comprisesa hydrophilic medium surface fumed silica having a specific surface areaof 200 square meters per gram, a content of greater than 99.8% silicondioxide, and a volume mass of 25-60 grams per liter. The strengtheningfiller increases tensile strength in the cured product, and must beadded under high shear mixing to ensure complete dispersion.

In yet another aspect of the roof caulk, the mineral filler comprises aground crystalline silica powder having a content of 98.5% silicondioxide, a particle size of 5.0 microns, a specific gravity of 2.65, aHegman fineness of 7.0-7.5, and a Mohs hardness of 7.0. The mineralfiller is added to increase hardness, tenacity, and volume of thefinished product.

In yet another aspect of the roof caulk, the pigment comprises a rutiletitanium dioxide pigment having a content of 91% titanium dioxide, aspecific gravity of 4.0, a pH of 7.5, and an average particle size of0.23 square micrometers. The pigment is extremely durable and improveslight reflectivity of the roof sealing system, which reduces transferredheat into the substrate and underlying roof and building structure.

In this embodiment, two crosslinking agents are used to achieveeffective curing of the product. Methyltris(methylethylketoxime)silaneand a blend of 90 weight percent methyltris(methylethylketoxime)silaneand 10 weight percent tetra(methylethylketoxime) silane oximecrosslinking agents are utilized. Methyltris(methylethylketoxime)silanehas a density of 0.9750 grams per cube centimeter at 20 Celsius and theappearance of a colorless transparent liquid. The blend of 90 percentmethyltris(methylethylketoxime)silane and 10 percenttetra(methylethylketoxime) silane has a variable density and theappearance of a colorless transparent liquid. These crosslinking agentsare added according to the molar quantity required to ensure a desiredcrosslink density in the cured product. In the presence of a dibutyltindilaurate catalyst, these crosslinking agents react with the roofingsystem resulting in exposure to ambient moisture causing the formationof crosslinked, elastomeric silicones, effectively curing the product.

In this embodiment, the adhesion promoter comprisesaminoethylaminopropyl-trimethoxysilane adhesion promoter having aminimum purity of 97%, a molecular weight of 222.36 atomic mass units, adensity of 1.028 grams per cube centimeter, and a boiling point of 259Celsius. The purpose of the adhesion promoter is to improve adherence ofthe roofing system to the roof substrate. This is achieved by using thesilane adhesion promoter as a coupling agent to provide elongation,flexibility, and spreading at the interface of the silicone polymer.This promotes adhesion between the roofing system and the roof surfaceby introducing reactive amino groups that facilitate adhesion betweenthe polymer and roof surface.

Additionally in this embodiment, the catalyst comprises a tin-baseddibutyltin dilaurate catalyst having a tin content of 17-19%, a densityof 1.07 grams per cube centimeter and a refractive index of 1.471 at 25Celsius, and a boiling point of 204 Celsius. In this aspect, thecatalyst is added to adjust the cure characteristics of the roofingsystem by promoting rapid gelation of the silicone roof sealing systemand tack-free drying time. Additionally, this catalyst improvesmechanical properties in the cured roof membrane.

With regard to fiber in this embodiment, the fiber comprises afibrillated high density polyethylene fiber having an average length of0.6 millimeters, diameter of 5 microns, and surface area of 12 squaremeters per gram. The fiber is added increase tenacity and scratchresistance in the finished product, and may increase the viscosity basedon length and diameter of the fiber. The fibrillation ensures effectivecrosslinking, making the caulk more robust.

Additionally, in this embodiment, one having ordinary skill in the artwill understand that several other ingredients can be substituted inplace of the ones listed. In this embodiment, substitutions can be madefor the polymer resin, strengthening fillers, mineral fillers, pigment,crosslinking agents, adhesion promoter, catalyst, and fiber.

In this embodiment, the silicone resin may comprise any organosiliconcompound of functionally similar viscosity to that described in thisapplication, including, for example polydimethylsiloxanes, such asendcapped-polydimethylsiloxane, OH-endcapped polydimethylsiloxane,polyhexamethyldisiloxane, octamethyltrisiloxane,decamethyltetrasiloxane, dodecamethylpentasiloxane, polyethylsiloxane,hydroxypropyl terminated polydimethylsiloxane, hydroxyl terminateddimethyl-methylvinyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl siloxane, silinol terminated dimethyl-diphenylpolysiloxane, hydroxyl terminated poly(methyl-trifluoropropyl)siloxane,or combinations thereof.

In this embodiment, the strengthening filler can comprise anyhydrophilic fumed silica having similar purity and surface area as thefumed silica mentioned above.

In this embodiment, the mineral filler may be comprised of calciumcarbonate, barium sulfate, iron oxide, diatomaceous earth, melamine,quartz, crystalline silica, amorphous silica, fumed silica, titaniumdioxide, alumina trihydrate, zinc oxide, zirconium oxide, zirconiumsilicate, zinc borate, chromic oxide, crystalline silica fine powder,amorphous silica fine powder, fumed silica powder, silicone rubberpowder, glass powder, silica hydrogen, silica aero gel, calciumsilicate, aluminum silicate, aluminum oxide, ferrite, carbon black,graphite, mica, clay, bentonite, or any combination thereof.

In this embodiment, the pigment may be comprised of zinc oxide, antimonyoxide, zirconium oxide, chromium oxide, iron oxide, lead oxide, zincsulfide, titanium dioxide, lithopone, or any combination thereof.

In this embodiment, the crosslinking agents may comprise any ketoximesilane including, but not limited to, phenyltris(methylethylketoxime)silane, vinyl tris(methylethylketoxime)silane,dimethyl bis(methylethylketoxime)silane,tetra(methylethylketoxime)silane, methyltris(methylethylketoxime)silane, or any combination thereof.

In this embodiment, the adhesion promoter may be comprised ofaminoethylaminopropyl-trimethoxysilane, 3-(2-Aminoethylamino)propyldimethoxymethylsilane, N-3-(Trimethoxysilyl)propylethylenediamine,vinyltris(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane,2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane,3-glycidoxypropyltrimethoxysilane,3-glycidoxypropylmethyldiethoxysilane,N-(2-aminoethyl)3-aminopropyltrimethoxysilane,3-aminopropyltriethoxysilane,3-(N-aminomethylbenzylamino)propyltrimethoxysilane,3-mercaptopropyltrimethoxysilane,3-aminopropyltris(methylethylketoxime)silane, 3-glycidoxypropyltriisopropenoxysilane, and3-glycidoxypropylmethyldiisopropenoxysilane, or any combination thereof.

In this embodiment, the catalyst may be comprised of dibutyltindiacetate, stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate,dibutyltin dimethoxide, dibutyltin bis(acetylacetonate), dibutyltinbis(benzylmalate), dimethyltin dimethoxide, dimethyltin diacetate,dioctyltin dioctate, dioctyltin dilaurate, tin dioctate, tin laulate,tetraisopropyl titanate, tetra-n-butyl titanate, tetra-tertiary butyltitanate, tetra-n-propyl titanate, tetra-2-ethylhexyl titanate,diisopropyl di-tertiary butyl titanate, dimethoxy titaniumbisacetylacetonate, diisopropoxy titanium bisethyl acetoacetate,di-tertiary butoxy titanium bisethyl acetoacetate, and di-tertiarybutoxy titanium bismethyl acetoacetate, or any combination thereof.

In this embodiment, the fiber may be comprised of any polymer, naturalfibers such as cotton, flax, jute, hemp or sisal, cellulose, ceramic,glass or the like. In accordance with this embodiment, the fiber may bea plant fiber, mineral fiber, synthetic fiber, regenerated fiber, orsemi-synthetic fiber. Synthetic fibers may be selected from the groupconsisting of polyethylene, polyethylene terephthalate, polyurethane,polypropylene, polyester, polyamide, nylon, polyacrylonitrile,poly-paraphenyulene terepthalamide, aramids, or combinations thereof.

Table 1, below, sets for an example of a formulation of the roof caulkin accordance with the present invention, in addition to preferred orpermissible ranges of each component in the formulation:

TABLE 1 Permissible Component Wt % Range Silicone Polymer Resin 55.3540.35-70.0  Pigment 5.0  5.0-13.0 Mineral Filler 24.7 15.0-40.0Strengthening Filler 5.6 2.0-8.0 Crosslinker 1 5.3  3.0-13.0 Crosslinker2 2.75 0.0-5.0 Adhesion Promoter 0.8 0.2-1.0 Fiber 0.4 0.1-2.0 Catalyst0.1 0.0-1.0

Mastic

The roof mastic of the system comprises similar ingredients and asimilar formulation as the roof coating, except that the mastic has ahigher viscosity than the coating to allow it to be spread by trowelingas opposed to application by brush, roller, or sprayer. The higherviscosity is achieved by increased size and fiber content, which employstwo fiber components as opposed to one in the coating.

As shown in FIG. 1A, the roof mastic is applied on top of the roof caulk520. Viscosity of the mastic is lower than caulk. Mastic is designed tobe delivered by trowel application to build up areas and fill largergaps prior to applying coating 520.

In this embodiment, the roof mastic may be comprised of a siliconepolymer resin, strengthening fillers, mineral fillers, solvent, pigment,crosslinking agents, adhesion promoters, catalyst, and inert fibercombined under high shear mixing and blanketed by nitrogen.

In one aspect of the roof mastic, the silicone polymer resin comprises ahydroxyl endcapped polydimethylsiloxane silanol fluid having a viscosityof 2,000 centipoise, specific gravity of 0.980, and refractive index of1.4058, at 25 degrees Celsius. Condensation curing is the mechanismemployed to cure the system, and achieved using the oxime crosslinkingagent and catalyst discussed below.

In another aspect of the roof mastic, the strengthening filler comprisesa hydrophilic medium surface fumed silica having a specific surface areaof 200 square meters per gram, a content of greater than 99.8% silicondioxide, and a volume mass of 25-60 grams per liter. The strengtheningfiller increases tensile strength in the cured product, and must beadded under high shear mixing to ensure complete dispersion.

In yet another aspect of the roof mastic, the mineral filler comprises aground crystalline silica powder having a content of 98.5% silicondioxide, a particle size of 5.0 microns, a specific gravity of 2.65, aHegman fineness of 7.0-7.5, and a Mohs hardness of 7.0. The mineralfiller is added to increase hardness, tenacity, and volume of thefinished product.

In yet another aspect of the roof mastic, the cyclic siloxane solventused comprises a decamethylcyclopentasiloxane having a content of 96.0%decamethylcyclopentasiloxane. This cyclic siloxane is volatile organiccompound (VOC) exempt, and gives off no VOC's during installation,curing, or its useful lifetime. The cyclic siloxane may be added toadjust the viscosity of the composition.

In this embodiment, the pigment comprises a rutile titanium dioxidepigment having a content of 91% titanium dioxide, a specific gravity of4.0, a pH of 7.5, and an average particle size of 0.23 squaremicrometers. The pigment is extremely durable and improves lightreflectivity of the roof sealing system, which reduces transferred heatinto the structure.

In this embodiment, two crosslinking agents are used to achieveeffective curing of the product. Methyltris(methylethylketoxime)silaneand a blend of 90 weight percent methyltris(methylethylketoxime)silaneand 10 weight percent tetra(methylethylketoxime) silane oximecrosslinking agents are utilized. Methyltris(methylethylketoxime)silanehas a density of 0.9750 grams per cube centimeter at 20 Celsius and theappearance of a colorless transparent liquid. The blend of 90 percentmethyltris(methylethylketoxime)silane and 10 percenttetra(methylethylketoxime) silane has a variable density and theappearance of a colorless transparent liquid. These crosslinking agentsare added according to the molar quantity required to ensure the correctcrosslink density in the cured product. In the presence of thedibutyltin dilaurate catalyst, these crosslinking agents react withambient moisture causing the formation of crosslinked, elastomericsilicones, effectively curing the product.

In this embodiment, the adhesion promoter comprises anaminoethyl-aminopropyltrimethoxysilane adhesion promoter having aminimum purity of 97%, a molecular weight of 222.36 atomic mass units, adensity of 1.028 grams per cube centimeter, and a boiling point of 259Celsius. The purpose of the adhesion promoter is to improve adherence ofthe roofing system to the roof substrate. This is achieved by using thesilane adhesion promoter as a coupling agent to provide elongation,flexibility, and spreading at the interface of the silicone polymer.This promotes adhesion between the roofing system and the roof surfaceby introducing reactive amino groups that facilitate adhesion betweenthe polymer and roof surface.

In this embodiment, the catalyst comprises a tin based dibutyltindilaurate catalyst having a tin content of 17-19%, a density of 1.07grams per cube centimeter and a refractive index of 1.471 at 25 Celsius,and a boiling point of 204 Celsius. This catalyst is added to adjust thecure characteristics of the roofing system by promoting rapid gelationof the silicone roof sealing system and tack-free drying time.Additionally, this catalyst improves mechanical properties in the curedroof membrane.

With regard to fiber in this embodiment, two different sized fibers areadded to increase the viscosity and allow the mastic to be troweled on.The first inert fiber comprises a fibrillated high density polyethylenefiber having an average length of 0.6 millimeters, diameter of 5microns, and surface area of 12 square meters per gram. The second inertfiber comprises a fibrillated high density polyethylene fiber having anaverage length of 0.7 millimeters, diameter of 15 microns, and surfacearea of 8 square meters per gram. The fiber is added increase tenacityand scratch resistance in the finished product, and may increase theviscosity based on length and diameter of the fiber. The fibrillationensures effective crosslinking, making the mastic more robust.

Additionally, in this embodiment, one having ordinary skill in the artwill understand that several other ingredients can be substituted inplace of the ones listed. In this embodiment, substitutions can be madefor the polymer resin, strengthening fillers, mineral fillers, solvent,pigment, crosslinking agents, adhesion promoter, catalyst, and fiber.

In this embodiment, the silicone resin may comprise any organosiliconcompound of functionally similar viscosity to that described in thisapplication, including, for example polydimethylsiloxanes, such asendcapped-polydimethylsiloxane, OH-endcapped polydimethylsiloxane,polyhexamethyldisiloxane, octamethyltrisiloxane,decamethyltetrasiloxane, dodecamethylpentasiloxane, polyethylsiloxane,hydroxypropyl terminated polydimethylsiloxane, hydroxyl terminateddimethyl-methylvinyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl siloxane, silinol terminated dimethyl-diphenylpolysiloxane, hydroxyl terminated poly(methyl-trifluoropropyl)siloxane,or combinations thereof.

In this embodiment, the strengthening filler can comprise anyhydrophyllic fumed silica having similar purity and surface area as thefumed silica mentioned above.

In this embodiment, the mineral filler may be comprised of calciumcarbonate, barium sulfate, iron oxide, diatomaceous earth, melamine,quartz, crystalline silica, amorphous silica, fumed silica, titaniumdioxide, alumina trihydrate, zinc oxide, zirconium oxide, zirconiumsilicate, zinc borate, chromic oxide, crystalline silica fine powder,amorphous silica fine powder, fumed silica powder, silicone rubberpowder, glass powder, silica hydrogen, silica aero gel, calciumsilicate, aluminum silicate, aluminum oxide, ferrite, carbon black,graphite, mica, clay, bentonite, or any combination thereof.

In this embodiment, the solvent may be comprised of any cyclic siloxane,including, but not limited to, octamethylcyclotetrasiloxane,dodecamethylcyclohexasiloxane, decamethylcyclopentasiloxane, or anycombination thereof.

In this embodiment, the pigment may be comprised of zinc oxide, antimonyoxide, zirconium oxide, chromium oxide, iron oxide, lead oxide, zincsulfide, titanium dioxide, lithopone, or any combination thereof.

In this embodiment, the crosslinking agents may comprise any ketoximesilane including, but not limited to, phenyltris(methylethylketoxime)silane, vinyl tris(methylethylketoxime)silane,dimethyl bis(methylethylketoxime)silane,tetra(methylethylketoxime)silane, methyl tris(methylethylketoxime)silane(“MOS”), or any combination thereof.

In this embodiment, the adhesion promoter may be comprised ofaminoethylaminopropyl-trimethoxysilane, 3-(2-Aminoethylamino)propyldimethoxymethylsilane, N-3-(Trimethoxysilyl)propylethylenediamine,vinyltris(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane,2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane,3-glycidoxypropyltrimethoxysilane,3-glycidoxypropylmethyldiethoxysilane,N-(2-aminoethyl)3-aminopropyltrimethoxysilane,3-aminopropyltriethoxysilane,3-(N-aminomethylbenzylamino)propyltrimethoxysilane,3-mercaptopropyltrimethoxysilane,3-aminopropyltris(methylethylketoxime)silane, 3-glycidoxypropyltriisopropenoxysilane, and3-glycidoxypropylmethyldiisopropenoxysilane, or any combination thereof.

In this embodiment, the catalyst may be comprised of dibutyltindiacetate, stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate,dibutyltin dimethoxide, dibutyltin bis(acetylacetonate), dibutyltinbis(benzylmalate), dimethyltin dimethoxide, dimethyltin diacetate,dioctyltin dioctate, dioctyltin dilaurate, tin dioctate, tin laulate,tetraisopropyl titanate, tetra-n-butyl titanate, tetra-tertiary butyltitanate, tetra-n-propyl titanate, tetra-2-ethylhexyl titanate,diisopropyl di-tertiary butyl titanate, dimethoxy titaniumbisacetylacetonate, diisopropoxy titanium bisethyl acetoacetate,di-tertiary butoxy titanium bisethyl acetoacetate, and di-tertiarybutoxy titanium bismethyl acetoacetate, or any combination thereof.

In this embodiment, the fiber may be comprised of any polymer, naturalfibers such as cotton, flax, jute, hemp or sisal, cellulose, ceramic,glass or the like. In accordance with this embodiment, the fiber may bea plant fiber, mineral fiber, synthetic fiber, regenerated fiber, orsemi-synthetic fiber. Synthetic fibers may be selected from the groupconsisting of polyethylene, polyethylene terephthalate, polyurethane,polypropylene, polyester, polyamide, nylon, polyacrylonitrile,poly-paraphenyulene terepthalamide, aramids, or combinations thereof.

Table 2, below, sets for an example of a formulation of the roof masticin accordance with the present invention, in addition to preferred orpermissible ranges of each component in the formulation:

TABLE 2 Permissible Component Wt % Range Silicone Polymer Resin 50.040.0-70.0 Pigment 4.59  4.0-12.0 Mineral Filler 17.78 15.0-40.0 Solvent17.19  5.0-23.0 Strengthening Filler 1.83 2.0-8.0 Crosslinker 1 5.47 3.0-13.0 Crosslinker 2 1.81 0.0-5.0 Adhesion Promoter 0.73 0.2-1.0Fiber 1 0.5 0.1-2.0 Fiber 2 1.5 0.1-2.0 Catalyst 0.1 0.0-1.0

Coating

The roof coating comprises the third applied layer of the roof sealingsystem. As shown in FIG. 1A, the coating is applied to the entirety ofthe roof surface in two or more coats 530, 540. The coating is designedto be applied via spray, brush, or roller because the viscosity isgenerally lower than that of the caulk or mastic. In this embodiment,the roof surface is coated with one to two gallons of the roof coatingper 100 square feet. This application results in a wetted thicknesscomprising 16 thousands of an inch per coat before curing.

In this embodiment, the roof coating may be comprised of a siliconepolymer resin, strengthening fillers, mineral fillers, solvent, pigment,crosslinking agents, adhesion promoters, catalyst, and inert fibercombined under high shear mixing and blanketed by nitrogen.

In one aspect of the roof coating, the silicone polymer resin comprisesa hydroxyl endcapped polydimethylsiloxane silanol fluid having aviscosity of 2,000 centipoise, specific gravity of 0.980, and refractiveindex of 1.4058, at 25 degrees Celsius. Condensation curing is themechanism employed to cure the system, and achieved using the oximecrosslinking agent and catalyst discussed below.

In another aspect of the roof coating, the strengthening fillercomprises a hydrophilic medium surface fumed silica having a specificsurface area of 200 square meters per gram, a content of greater than99.8% silicon dioxide, and a volume mass of 25-60 grams per liter. Thestrengthening filler increases tensile strength in the cured product,and must be added under high shear mixing to ensure complete dispersion.

In yet another aspect of the roof coating, the mineral filler comprisesa ground crystalline silica powder having a content of 98.5% silicondioxide, a particle size of 5.0 microns, a specific gravity of 2.65, aHegman fineness of 7.0-7.5, and a Mohs hardness of 7.0. The mineralfiller is added to increase hardness, tenacity, and volume of thefinished product.

In yet another aspect of the roof coating, the cyclic siloxane solventcomprises a decamethylcyclopentasiloxane having a content of 96.0%decamethylcyclopentasiloxane. This cyclic siloxane is volatile organiccompound (VOC) exempt, and gives off no VOC's during installation,curing, or its useful lifetime. The cyclic siloxane is added because thehigh inert fiber content of the coating necessitates a solvent to reducethe viscosity.

In this embodiment, the pigment comprises a rutile titanium dioxidepigment having a content of 91% titanium dioxide, a specific gravity of4.0, a pH of 7.5, and an average particle size of 0.23 squaremicrometers. The pigment is extremely durable and improves lightreflectivity of the roof sealing system, which reduces transferred heatinto the structure.

In this embodiment, two crosslinking agents are used to achieveeffective curing of the product. Methyltris(methylethylketoxime)silaneand a blend of 90 weight percent methyltris(methylethylketoxime)silaneand 10 weight percent tetra(methylethylketoxime) silane oximecrosslinking agents are utilized. Methyltris(methylethylketoxime)silanehas a density of 0.9750 grams per cube centimeter at 20 Celsius and theappearance of a colorless transparent liquid. The blend of 90 percentmethyltris(methylethylketoxime)silane and 10 percenttetra(methylethylketoxime) silane has a variable density and theappearance of a colorless transparent liquid. These crosslinking agentsare added according to the molar quantity required to ensure the correctcrosslink density in the cured product. In the presence of thedibutyltin dilaurate catalyst, these crosslinking agents react with theroofing system resulting in exposure to ambient moisture causing theformation of crosslinked, elastomeric silicones, effectively curing theproduct.

In this embodiment, the adhesion promoter comprises anaminoethylaminopropyl-trimethoxysilane adhesion promoter having aminimum purity of 97%, a molecular weight of 222.36 atomic mass units, adensity of 1.028 grams per cube centimeter, and a boiling point of 259Celsius. The purpose of the adhesion promoter is to improve adherence ofthe roofing system to the roof substrate. This is achieved by using thesilane adhesion promoter as a coupling agent to provide elongation,flexibility, and spreading at the interface of the silicone polymer.This promotes adhesion between the roofing system and the roof surfaceby introducing reactive amino groups that facilitate adhesion betweenthe polymer and roof surface.

In this embodiment, the catalyst comprises a tin based dibutyltindilaurate catalyst having a tin content of 17-19%, a density of 1.07grams per cube centimeter and a refractive index of 1.471 at 25 Celsius,and a boiling point of 204 Celsius. This catalyst is added to adjust thecure characteristics of the roofing system by promoting rapid gelationof the silicone roof sealing system and tack-free drying time.Additionally, this catalyst improves mechanical properties in the curedroof membrane.

With regard to fiber in this embodiment, the inert fiber comprises afibrillated high density polyethylene fiber having an average length of0.6 millimeters, diameter of 5 microns, and surface area of 12 squaremeters per gram. The fiber is added increase tenacity and scratchresistance in the finished product, and may increase the viscosity basedon length and diameter of the fiber. The fibrillation ensures effectivecrosslinking, making the coating more robust.

Additionally, in this embodiment, one having ordinary skill in the artwill understand that several other ingredients can be substituted inplace of the ones listed. In this embodiment, substitutions can be madefor the polymer resin, strengthening fillers, mineral fillers, solvent,pigment, crosslinking agents, adhesion promoter, catalyst, and fiber.

In this embodiment, the silicone resin may comprise any organosiliconcompound of functionally similar viscosity to that described in thisapplication, including, for example polydimethylsiloxanes, such asendcapped-polydimethylsiloxane, OH-endcapped polydimethylsiloxane,polyhexamethyldisiloxane, octamethyltrisiloxane,decamethyltetrasiloxane, dodecamethylpentasiloxane, polyethylsiloxane,hydroxypropyl terminated polydimethylsiloxane, hydroxyl terminateddimethyl-methylvinyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl polysiloxane, hydroxyl terminateddimethyl-methylphenyl siloxane, silinol terminated dimethyl-diphenylpolysiloxane, hydroxyl terminated poly(methyl-trifluoropropyl)siloxane,or combinations thereof.

In this embodiment, the strengthening filler can comprise anyhydrophyllic fumed silica having similar purity and surface area as thefumed silica mentioned above.

In this embodiment, the mineral filler may be comprised of calciumcarbonate, barium sulfate, iron oxide, diatomaceous earth, melamine,quartz, crystalline silica, amorphous silica, fumed silica, titaniumdioxide, alumina trihydrate, zinc oxide, zirconium oxide, zirconiumsilicate, zinc borate, chromic oxide, crystalline silica fine powder,amorphous silica fine powder, fumed silica powder, silicone rubberpowder, glass powder, silica hydrogen, silica aero gel, calciumsilicate, aluminum silicate, aluminum oxide, ferrite, carbon black,graphite, mica, clay, bentonite, or any combination thereof.

In this embodiment, the solvent may be comprised of any cyclic siloxane,including, but not limited to, octamethylcyclotetrasiloxane,dodecamethylcyclohexasiloxane, decamethylcyclopentasiloxane, or anycombination thereof.

In this embodiment, the pigment may be comprised of zinc oxide, antimonyoxide, zirconium oxide, chromium oxide, iron oxide, lead oxide, zincsulfide, titanium dioxide, lithopone, or any combination thereof.

In this embodiment, the crosslinking agents may comprise any ketoximesilane including, but not limited to, phenyltris(methylethylketoxime)silane, vinyl tris(methylethylketoxime)silane,dimethyl bis(methylethylketoxime)silane,tetra(methylethylketoxime)silane, methyl tris(methylethylketoxime)silane(“MOS”), or any combination thereof.

In this embodiment, the adhesion promoter may be comprised ofaminoethylaminopropyl-trimethoxysilane, 3-(2-Aminoethylamino)propyldimethoxymethylsilane, N-3-(Trimethoxysilyl)propylethylenediamine,vinyltris(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane,2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane,3-glycidoxypropyltrimethoxysilane,3-glycidoxypropylmethyldiethoxysilane,N-(2-aminoethyl)3-aminopropyltrimethoxysilane,3-aminopropyltriethoxysilane,3-(N-aminomethylbenzylamino)propyltrimethoxysilane,3-mercaptopropyltrimethoxysilane,3-aminopropyltris(methylethylketoxime)silane, 3-glycidoxypropyltriisopropenoxysilane, and3-glycidoxypropylmethyldiisopropenoxysilane, or any combination thereof.

In this embodiment, the catalyst may be comprised of dibutyltindiacetate, stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate,dibutyltin dimethoxide, dibutyltin bis(acetylacetonate), dibutyltinbis(benzylmalate), dimethyltin dimethoxide, dimethyltin diacetate,dioctyltin dioctate, dioctyltin dilaurate, tin dioctate, tin laulate,tetraisopropyl titanate, tetra-n-butyl titanate, tetra-tertiary butyltitanate, tetra-n-propyl titanate, tetra-2-ethylhexyl titanate,diisopropyl di-tertiary butyl titanate, dimethoxy titaniumbisacetylacetonate, diisopropoxy titanium bisethyl acetoacetate,di-tertiary butoxy titanium bisethyl acetoacetate, and di-tertiarybutoxy titanium bismethyl acetoacetate, or any combination thereof.

In this embodiment, the fiber may be comprised of any polymer, naturalfibers such as cotton, flax, jute, hemp or sisal, cellulose, ceramic,glass or the like. In accordance with this embodiment, the fiber may bea plant fiber, mineral fiber, synthetic fiber, regenerated fiber, orsemi-synthetic fiber. Synthetic fibers may be selected from the groupconsisting of polyethylene, polyethylene terephthalate, polyurethane,polypropylene, polyester, polyamide, nylon, polyacrylonitrile,poly-paraphenyulene terepthalamide, aramids, or combinations thereof.

Table 3, below, sets for an example of a formulation of the roof coatingin accordance with the present invention, in addition to preferred orpermissible ranges of each component in the formulation:

TABLE 3 Permissible Component Wt % Range Silicone Polymer Resin 50.040.0-70.0 Pigment 4.59  4.0-12.0 Mineral Filler 17.78 15.0-40.0 Solvent17.19  5.0-23.0 Strengthening Filler 1.83 2.0-8.0 Crosslinker 1 5.47 3.0-13.0 Crosslinker 2 1.81 0.0-5.0 Adhesion Promoter 0.73 0.2-1.0Fiber 0.5 0.1-2.0 Catalyst 0.1 0.0-1.0

System Operation

In one embodiment of the operation of the system, the three componentsare applied in series to a roof to create a seamless, watertightmembrane on the roof surface. The roof sealing system can be applied onan existing membrane roof (such as PVC, EPDM, or Bitumen-based) ordirectly on to the decking. As shown in FIG. 1A, the method of operatingthe system may comprise the steps of clearing the roof of debris 500,applying the roof caulk to fill larger gaps in the substrate of the roof510, and seal any penetrations around pipes, vents, edges, joints,seams, and cracks 510, applying the mastic over the caulk to create asealed barrier and build up valleys and dips in the roof 520 to preventwater from pooling on the coating wherein the mastic smooths the surfacein preparation for application of the coating 520, applying the roofcoating to the entirety of the roof 530, in two or more applications 540with a roller, brush, or spray, to completely seal the surface of theroof, and allowing the system to cure 550.

In one embodiment, the silicone coating adheres to itself to form onesolid sheet of silicone polymer encompassing the entirety of the roofsurface. This embodiment forms a watertight barrier that does not haveseams or weak points. The coating cures from ambient moisture in theatmosphere via the well-understood process of condensation curing. Inareas of higher ambient moisture, cure time is lower. In thisembodiment, cure time may be between three and eight hours, nominally.Additionally, in this embodiment, the inert polyethylene fibers do notnecessitate any fabric reinforcing layer, and the lower viscosity of theroof sealing system allows for complete adherence to the roof surfacewithout the need for additional adhesives.

Method of Manufacture

In one embodiment, the three components are manufactured in a similarmethod with some variation in viscosity due to different length inertfibers, and the addition of the cyclic siloxane solvent in the masticand the coating. In this embodiment, as shown in FIG. 2A, hydroxylendcapped polydimethylsiloxane silicone polymers are added to a mixingvessel 100 and combined with crystalline ground silica mineral fillersto enhance hardness 110. Next, under high shear mixing, hydrophyllicfumed silica strengthening fillers are added to enhance tensile strengthof the cured product 120. In the roof mastic 180 and roof coating 140,cyclic siloxane is then added as a solvent to reduce viscosity. Thecyclic solvent is allowed to disperse until a Hegman test shows a grindof 7H or better. Decamethylcyclopentasiloxane is used as the cyclicsiloxane solvent. High shear mixing ensures complete dispersion of thesolvent. Titanium dioxide pigment paste is then added to the mixingvessel 130, 190, 250. The pigment paste is allowed to rest prior tobeing added to the mixing vessel to allow any entrained air to disperse.A nitrogen purge is utilized to expel any excess air and moisture 310.Methyl-tris-(methylethylketoxime) silane (“MOS”) and a blend of 90weight percent MOS and 10 weight percent tetra(methylethylketoxime)silane oxime crosslinking agents (“90/10 Crosslinker”) are then addedaccording to the molar quantity required to ensure a desired crosslinkdensity in the cured product 140, 200, 260. Anaminoethylaminopropyl-trimethoxysilane adhesion promoter is added toensure effective adherence to roofing substrates 150, 210, 270.Dibutyltin dilaurate catalyst is then added to adjust the curecharacteristics 160, 220, 280. All ingredients are mixed until they arehomogenized completely, still under the nitrogen purge 310. Finally,fibrillated polyethylene fibers are added to the mixture to increasetenacity and scratch resistance. In this embodiment, one fiber size isadded to the caulk 170 and the coating 290, and two fiber sizes areadded to the mastic 230. The caulk, mastic, and coating are then readyfor packaging and consumer use 300.

While the invention has been described in connection with variousembodiments, it will be understood that the invention is capable offurther modifications. This application is intended to cover anyvariations, uses or adaptations of the invention following, in general,the principles of the invention, and including such departures from thepresent disclosure as, within the known and customary practice withinthe art to which the invention pertains.

1. A sealant composition configured to seal a substrate comprising: apolymer resin base; fibers suspended in the polymer resin base; apigment; at least one crosslinking agent; an adhesion promoter; at leastone filler material; and a curing catalyst.
 2. The sealant compositionof claim 1, wherein the sealant composition comprises a first state anda second state, the sealant composition being in the first state priorto being applied and is in a gel or liquid form, and in the secondstate, the sealant composition is cured and in a solid form.
 3. Thesealant composition of claim 1, wherein the sealant composition is acaulk.
 4. The sealant composition of claim 3, wherein the polymer resinbase present in the range of about 40.35 to 70.0% by weight; the pigmentpresent in the range of about 5.0 to 13.0% by weight; the at least onefiller material present in the range of about 17.0 to 48.0% by weight;the at least one crosslinking agent present in the range of about 3.0 to18.0% by weight; the adhesion promoter present in the range of about 0.2to 1.0% by weight; the fibers present in the range of about 0.1 to 2.0%by weight; and the curing catalyst present in the range of about 0 to1.0% by weight.
 5. The sealant composition of claim 1, wherein thesealant composition is a mastic, further comprising a solvent.
 6. Thesealant composition of claim 5, wherein the polymer resin base presentin the range of about 40.0 to 70.0% by weight; the pigment present inthe range of about 4.0 to 12.0% by weight; the at least one fillermaterial present in the range of about 17.0 to 48.0% by weight; the atleast one crosslinking agent present in the range of about 3.0 to 18.0%by weight; the adhesion promoter present in the range of about 0.2 to1.0% by weight; the solvent present in the range of about 5.0 to 23.0%by weight; at least two different fibers, the fibers present in therange of about 0.2 to 4.0% by weight; and the curing catalyst present inthe range of about 0 to 1.0% by weight.
 7. The sealant composition ofclaim 5, wherein the solvent is a siloxane selected fromoctamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane,decamethylcyclopentasiloxane, or any combination thereof.
 8. The sealantcomposition of claim 1, wherein the sealant composition is a coating,further comprising a solvent.
 9. The sealant composition of claim 8,wherein the polymer resin base present in the range of about 40.0 to70.0% by weight; the pigment present in the range of about 4.0 to 12.0%by weight; the at least one filler material present in the range ofabout 17.0 to 48.0% by weight; the at least one crosslinking agentpresent in the range of about 3.0 to 18.0% by weight; the adhesionpromoter present in the range of about 0.2 to 1.0% by weight; thesolvent present in the range of about 5.0 to 23.0% by weight; at leastone fiber, the fiber present in the range of about 0.1 to 2.0% byweight; and the curing catalyst present in the range of about 0 to 1.0%by weight.
 10. The sealant composition of claim 8, wherein the solventis a siloxane selected from octamethylcyclotetrasiloxane,dodecamethylcyclohexasiloxane, decamethylcyclopentasiloxane, or anycombination thereof.
 11. The sealant composition of claim 1, wherein thepolymer resin base is an organosilane.
 12. The sealant composition ofclaim 1, wherein the fibers are selected from the group consisting ofplant fiber, mineral fiber, synthetic fiber, regenerated fiber, andsemi-synthetic fiber, and combinations thereof.
 13. The sealantcomposition of claim 12, wherein the fibers are a synthetic fiberselected from the group consisting of polyethylene, polyethyleneterephthalate, polyurethane, polypropylene, polyester, polyamide, nylon,polyacrylonitrile, poly-paraphenyulene terepthalamide, and aramids, andcombinations thereof.
 14. The sealant composition of claim 1, whereinthe pigment is selected from zinc oxide, antimony oxide, zirconiumoxide, chromium oxide, iron oxide, lead oxide, zinc sulfide, titaniumdioxide, lithopone, or any combination thereof.
 15. The sealantcomposition of claim 1, wherein the at least one crosslinking agent is asilane.
 16. The sealant composition of claim 15, wherein the silane is aketoxime silane selected from the group consisting of phenyltris(methylethylketoxime)silane, vinyl tris-(methylethylketoxime)silane,dimethyl bis(methylethylketoxime)silane,tetra(methylethylketoxime)silane, methyltris(methylethylketoxime)silane, and combinations thereof.
 17. Thesealant composition of claim 1, wherein the adhesion promoter isselected from aminoethylaminopropyl-trimethoxysilane,3-(2-Aminoethylamino) propyldimethoxymethylsilane,N-3-(Trimethoxysilyl)propylethylenediamine,vinyltris(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane,2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane,3-glycidoxypropyltrimethoxysilane,3-glycidoxypropylmethyldiethoxysilane,N-(2-aminoethyl)3-aminopropyltrimethoxysilane,3-aminopropyltriethoxysilane,3-(N-aminomethylbenzylamino)propyltrimethoxysilane,3-mercaptopropyltrimethoxysilane,3-aminopropyltris(methylethylketoxime)silane, 3-glycidoxypropyltriisopropenoxysilane, and3-glycidoxypropylmethyldiisopropenoxysilane, or any combination thereof.18. The sealant composition of claim 1, wherein the curing catalyst isselected from dibutyltin diacetate, stannous octoate, dibutyltindioctoate, dibutyltin dilaurate, dibutyltin dimethoxide, dibutyltinbis(acetylacetonate), dibutyltin bis(benzylmalate), dimethyltindimethoxide, dimethyltin diacetate, dioctyltin dioctate, dioctyltindilaurate, tin dioctate, tin laulate, tetraisopropyl titanate,tetra-n-butyl titanate, tetra-tertiary butyl titanate, tetra-n-propyltitanate, tetra-2-ethylhexyl titanate, diisopropyl di-tertiary butyltitanate, dimethoxy titanium bisacetylacetonate, diisopropoxy titaniumbisethyl acetoacetate, di-tertiary butoxy titanium bisethylacetoacetate, and di-tertiary butoxy titanium bismethyl acetoacetate, orany combination thereof.
 19. A sealing system configured to be capableof being applied to a roof substrate, comprising: a sealing caulk havinga viscosity configured to allow the sealing caulk to be dispensed from apressurized tube in a bead adapted to fill pre-existing seams, joints,and cracks for pipes, vents, and structural edges; a mastic having aviscosity configured to allow the mastic to be spread over the sealingcaulk and uneven surfaces; and a coating for layering over the sealingcaulk, the mastic and the roof substrate, wherein the sealing caulk, themastic, and the coating all comprise a silicone polymer material and aninert fiber infused within the silicone polymer material; and whereinthe coating has at least two layers applied to the roof substrate.
 20. Amethod of applying a sealant system to a roofing substrate, comprisingthe steps of: clearing a targeted area of any debris or obstacles of theroofing substrate; providing the sealant system, comprising of a caulk,a mastic gap filler, and a coating, wherein the caulk, the mastic gapfiller, and the coating comprise a polymer base material and inertfibers infused within the polymer base material; applying the caulk tocoat all pre-existing seams, cracks in structural features, gaps betweenstructural features, or joints located within the targeted area;overlaying the mastic gap filler over the caulk forming a seal over anyof pre-existing seams, cracks in structural features, gaps betweenstructural features, or joints located within the targeted area; coatingthe roofing substrate with a first application; applying a secondapplication of the coating while the first application is tacky or fullycured to provide the roofing substrate with a watertight barrier; andcuring the coating on the roofing substrate.
 21. The method of applyingthe sealant system of claim 20, wherein curing is facilitated by ambientmoisture via condensation curing.
 22. The method of applying the sealantsystem of claim 20, wherein fibers are a synthetic fiber selected fromthe group consisting of polyethylene, polyethylene terephthalate,polyurethane, polypropylene, polyester, polyamide, nylon,polyacrylonitrile, poly-paraphenyulene terepthalamide, and aramids, andcombinations thereof.
 23. The method of applying the sealant system ofclaim 20, wherein overlaying the mastic gap filler over the caulkcreates a substantially flat surface for which to apply the coating.